Food tray device and method

TECHNICAL FIELD

This invention relates to a food tray device and method that may be used to keep food heated or cooled. The food tray device and method of the present invention is particularly suited for use in heated compartments used in quick-service restaurants to store cooked food product, for example.

BACKGROUND OF THE INVENTION

Quick-service restaurants face a number of conflicting factors when striving to efficiently provide fast, good tasting, and safe food. First, customers expect to receive their food quickly, with a minimum of delay and with predictable and constant high quality. Moreover, the rate of customer demand varies over time, with some periods, such as lunch and dinner times, having extremely high rates of customer demand. However, the kitchens of many quick-service restaurants are of limited size and/or production capacity and thus necessarily have a limited number of food cooking devices.

To meet the often competing factors of quick service and consistent high quality, it is advantageous for a crew person to cook a relatively substantial amount of food product in bulk and store the cooked food product in food trays while another crew person transfers food from the trays to a sandwich bun or individual portion sized container, for example, to fill customer orders. Typical food products that are of most interest to have readily available for crew persons include sandwich fillings such as hamburger patties, breaded fish fillets, Canadian bacon, pork sausage, eggs, and breaded chicken patties, for example, as well as other products, such as chicken nuggets, biscuits, muffins, and hotcakes.

Because these prepared food products, e.g., sandwich fillings, are not being served immediately upon preparation, it is important to store the food product so as to optimally maintain the appearance, taste, temperature and texture of the food product, as well as minimize bacterial contamination of the stored food product.

A need exists for an improved food tray and a method of using the food tray that optimizes, without any significant adverse effects, the appearance, taste, temperature and texture of the pre-cooked bulk food products, as well as minimize bacterial contamination of such stored food products. In addition, a need also exists for a food staging device that promotes efficient food handling and use of space within the kitchen of the quick-service restaurant.

Additionally, prior art food trays were required to be periodically cleaned and dried, such as after about every four hours of use. In quick-service restaurants having extended opening hours during which food is served throughout the day, food trays may be cleaned as many as five or six times per day. During the time of cleaning, the trays are unavailable for holding cooked food. Thus, there is a need for a food tray that is more efficient.

SUMMARY OF THE INVENTION

In accordance with the present invention, a device which is an improved food tray and a method is provided, typically for use in connection with a food storage compartment, and preferably in a heated pass-through compartment, for holding ready-to-serve food products. When used in combination with a compartment of desirable configuration, the food tray device is particularly useful for storing over an extended period of time various types of food products including cooked sandwich fillings such as, for example, hamburger patties, fish fillets, Canadian bacon, pork sausage, eggs, chicken patties, chicken fillets as well as other types of food, including chicken nuggets, biscuits, muffins, and hotcakes. The appearance, taste, temperature and texture of the stored food items may be maintained over extended storage periods while also minimizing risk of bacterial contamination. In addition, the trays do not require extended cleaning and drying times.

In one aspect of the invention, a tray for holding cooked food portions at an elevated temperature is provided. The tray has a tray portion or container and a support. Typically, the tray portion substantially fits within the support, which substantially surrounds the sidewalls of the tray portion or container. The container has an open top, a bottom and a sidewall structure. The bottom and the sidewall structure of the container define an interior volume for containing the cooked food portions. The support has an open bottom. The container is removably disposed in the support and the container extends through the open bottom for allowing an external heated surface to contact the bottom of the container. The support is rigid compared to the container. Preferably, the container is supported by (1) an outwardly expanding top edge of the sidewall structure on the top of the support, and (2) an indentation in the sidewall structure. Typically, the container is a thin-walled plastic thereby requiring only a relatively small amount of material for construction and thus can be used as a disposable container. In this manner, washing or cleaning of the container is avoided during normal (disposable) use. Thus, the tray portion or container need not be capable of being able to carry or reliably carry food therein as a self-supporting structure without bending or otherwise collapsing or otherwise failing, in the absence of the support, such as if grasped at one end while filled or substantially filled with a food product without the support. Typically, the container is a thin-walled disposable container as described above.

In another aspect of the invention, an apparatus for holding previously cooked food portions at an elevated temperature is provided. The apparatus has at least one heated doorless compartment, a cabinet for housing the at least one compartment therein, and at least one tray placeable into the at least one compartment. The compartment has an upper compartment surface and a heated lower surface. The cabinet includes at least one cabinet opening for inserting and removing the previously cooked food portions into and out of said compartment. The tray has a container and a support. The container has an open top, a bottom and a sidewall structure. The bottom and the sidewall structure define an interior volume for containing the cooked food portions. The support has an open bottom and the container is removably disposed inside the support. The apparatus also has a means for supporting the tray in the compartment so that the bottom of the container is in contact with the heated lower surface and the top edge of the tray is spaced from the upper compartment surface.

In a third aspect of the invention, a method of storing a cooked food item is provided. The method includes providing a container having an open top, a bottom and a sidewall structure, the bottom and the sidewall structure defining an interior volume and providing a support having a support opening. Next, the container is placed into the support opening thereby forming a tray and the cooked food item is placed in the tray to at least partially fill the interior volume. Next, the tray having the cooked food therein is placed into a compartment having a heated surface so that the bottom of the container contacts the heated surface to maintain the temperature of the food in a desired elevated temperature range.

In a fourth aspect of the invention, a method of handling cooked food portions to be incorporated into a sandwich in a restaurant is provided. The method includes providing a container having an open top, a bottom and a sidewall structure, the bottom and the sidewall structure defining an interior volume and providing a support having a support opening. Next, the container is placed into the support opening thereby forming a tray and the cooked food item is placed in the tray to at least partially fill the interior volume. Next, the tray having the cooked food therein is placed into a compartment having a heated surface so that the bottom of the container contacts the heated surface to maintain the temperature of the food in a desired elevated temperature range. Then, the cooked food portion is removed from the tray and a sandwich is assembled using the cooked food portion from the tray.

BRIEF DESCRIPTION OF THE DRAWINGS

<figref idref="DRAWINGS">FIG. 1</figref> is a perspective view of a first embodiment of a tray holding cooked food portions;

<figref idref="DRAWINGS">FIG. 2</figref> is an exploded view of the first embodiment of the tray holding cooked food portions;

<figref idref="DRAWINGS">FIG. 3</figref> is a side view of the first embodiment of the tray supported by the support;

<figref idref="DRAWINGS">FIG. 4</figref><i>a </i>is an enlarged view of the first embodiment of the tray inside a cabinet; <figref idref="DRAWINGS">FIG. 4</figref><i>b </i>is an enlarged view of a portion of <figref idref="DRAWINGS">FIG. 4</figref><i>a; </i>

<figref idref="DRAWINGS">FIG. 5</figref> is a side view of the container of a second embodiment of a tray;

<figref idref="DRAWINGS">FIG. 6</figref> is a perspective view of the support of the second embodiment of the tray;

<figref idref="DRAWINGS">FIG. 7</figref> is an exploded view of the second embodiment of the tray;

<figref idref="DRAWINGS">FIG. 8</figref> is a perspective view of the first embodiment of the tray being inserted into a cabinet;

<figref idref="DRAWINGS">FIG. 9</figref> is a broken away side view of the first embodiment of the tray inside a cabinet;

<figref idref="DRAWINGS">FIG. 10</figref> is an exploded view of a third embodiment of the tray; and

<figref idref="DRAWINGS">FIG. 11</figref> is a perspective view of the third embodiment of the tray.

DETAILED DESCRIPTION OF THE INVENTION

Food Tray

Referring to the Figures generally, two principal embodiments of the inventive tray are described herein. The first embodiment tray <b>100</b> is shown in <figref idref="DRAWINGS">FIGS. 1-4</figref>, and the second embodiment is shown in <figref idref="DRAWINGS">FIGS. 5-7</figref>. Tray <b>100</b> is composed of a disposable container or tray portion <b>102</b> and a support <b>104</b>. Disposable container <b>102</b> has an open top <b>106</b>, a bottom <b>108</b> and a sidewall structure <b>110</b>. Bottom <b>108</b> and sidewall structure <b>110</b> are not perforated so that liquids or crumbs will not fall through. Bottom <b>108</b> and sidewall structure <b>110</b> define an interior volume <b>112</b> for containing cooked food portions stored therein, in this case being six (6) hamburger patties HP, stacked two high. Disposable container <b>102</b> is removably disposed in support <b>104</b>. Disposable container <b>102</b> extends through an open bottom <b>114</b> of support <b>104</b> allowing bottom <b>108</b> to contact a heated surface which will be discussed in greater detail later.

Sidewall structure <b>110</b> of disposable container <b>102</b> has opposing end walls <b>122</b><i>a </i>and <b>122</b><i>b </i>and opposing sidewalls <b>124</b><i>a </i>and <b>124</b><i>b</i>. Sidewall structure <b>110</b> has rounded reinforced corners <b>126</b>. Corners <b>126</b> have a reinforcing groove <b>128</b> or a plurality of grooves (not shown). Groove <b>128</b> does not extend throughout the length of sidewall structure <b>110</b> and is preferably substantially limited to the region of each corner <b>126</b>. Groove <b>128</b> is preferably substantially parallel to bottom <b>108</b> so as to extend from an end wall <b>122</b> to a sidewall <b>124</b> by a direct path. Groove <b>128</b> may be at any height. Preferably, groove <b>128</b> is closer to a lip <b>130</b> than to bottom <b>108</b>.

Lip <b>130</b> is one of several structures for supporting disposable container <b>102</b>. Lip <b>130</b> is an outwardly expanding top edge of sidewall structure <b>110</b>. Another supporting structure is indentation <b>132</b> in sidewall structure <b>110</b>. As shown indentation <b>132</b> is at the junction of the sidewall structure <b>110</b> and bottom <b>108</b>, but there could be a second or alternative indentation (not shown) located at a different height in sidewall structure <b>110</b>. Preferably indentation <b>132</b> extends substantially along the length of sidewalls <b>124</b><i>a </i>and <b>124</b><i>b</i>. Preferably, indentation <b>132</b> extends substantially along the length of endwalls <b>122</b><i>a </i>and <b>122</b><i>b</i>. Most preferably, indentation <b>132</b> extends substantially along the entire length of sidewall structure <b>110</b>. Corresponding structures in the support for supporting the container are discussed later.

Generally, the interior volume <b>112</b> is substantially rectangular or square in cross-section. Interior volume <b>112</b> is typically not perfectly rectangular or square due to the structures discussed above and because sidewall structure <b>110</b> preferably slopes inwardly from top to bottom to permit disposable containers <b>102</b> to nest inside each other, but can be as desired. Typically, the angle between sidewall structure <b>110</b> and bottom <b>108</b> omitting indentation <b>132</b> is between 105 and 90 degrees, more typically between about 100 and 91 degrees, and still more typically between about 98 and 93 degrees. Generally, sidewalls <b>124</b><i>a </i>and <b>124</b><i>b </i>are longer than endwalls <b>122</b><i>a </i>and <b>122</b><i>b, </i>preferably by a factor of 2 or more and more typically by a factor of 3 or more, but can be as desired.

Support <b>104</b> has a top <b>134</b>, bottom <b>114</b> and sidewall structure <b>138</b>. Top <b>134</b> has an opening <b>140</b> allowing disposable container <b>102</b> to be inserted into and removed from support <b>104</b>. Top <b>134</b> has a recessed surface <b>142</b> for receiving lip <b>130</b>. Bottom <b>114</b> is open. Bottom <b>114</b> is typically considered open if at least 90% of bottom <b>114</b> is open and/or so that bottom <b>108</b> can extend through bottom <b>114</b> to contact a heated surface. In addition to lip <b>130</b>, disposable container <b>102</b> is supported by various support structures of support <b>104</b>. One preferred support structure is a ledge <b>144</b>, which engages indentation <b>132</b>. An alternative or additional support structure is one or more joists (not pictured) running from sidewall <b>146</b><i>a </i>to sidewall <b>146</b><i>b </i>of sidewall structure <b>138</b> or from endwall <b>148</b><i>a </i>to endwall <b>148</b><i>b </i>of sidewall structure <b>138</b>, for example and allowing disposable container <b>102</b> to extend between joists to contact a heated surface. A fourth support structure is sidewall structure ledge <b>150</b>. A corresponding indentation in disposable container <b>102</b> is not illustrated. Ledges <b>144</b> and <b>150</b> may extend along the entirety or a portion of support sidewall structure <b>138</b>. Preferably, ledges <b>144</b> or <b>150</b> extend substantially along the length of sidewalls <b>146</b><i>a </i>and <b>146</b><i>b</i>. Preferably, ledges <b>144</b> or <b>150</b> extend substantially along the length of endwalls <b>148</b><i>a </i>and <b>148</b><i>b. </i>

Support <b>104</b> is preferably reusable while disposable container <b>102</b> is preferably disposable. While disposable container <b>102</b> is self-supporting, it preferably does not support the weight of food when disposable container <b>102</b> is held at one end without buckling. In contrast, support <b>104</b> is intended to be reused many times and is capable of supporting disposable container <b>102</b> when filled with food products without the support deforming. Consequently, support <b>104</b> is rigid relative to disposable container <b>102</b>. Bottom <b>108</b> and sidewall structure <b>110</b> of disposable container <b>102</b> are preferably thin walled and thus flexible and have a high coefficient of heat transfer, higher than that of support <b>104</b>. One or both of disposable container <b>102</b> and support <b>104</b> are preferably integrally formed from plastic, but alternatively may be formed from any other suitable “food safe” material. Suitable materials include polystyrene, polycarbonate, polyethylene, polypropylene, stainless steel, aluminum or other materials as desired. For example, in one embodiment, support <b>104</b> is about 2 inches high, about 4⅝ inches wide across the top opening, about 3⅛ inches wide across the bottom opening, about 18 ⅝ inches long across the top opening and about 17⅛ inches long across the bottom opening and has a weight of about 10.4 ounces and is made of polycarbonate and has a thickness of about 0.0625 inches and disposable container <b>102</b> is about 2.2 inches high, about 4.5 inches wide across the top opening, about 3¾ inches across the bottom, about 18.5inches long across the top opening, about 17- 13/16 long at the bottom and a lip <b>130</b> width of 7/16 inches, has a weight of about 1.1 ounces and is made of polystyrene. Thus, disposable container or tray portion <b>102</b> can be fabricated from a very small amount of material and thus can be disposably and economically used in and can be a thin-walled container having a wall thickness, for example, of less than about 0.035 inches in one embodiment and can be a thin-walled container having a wall thickness of less than about 0.025 inches in another embodiment.

Support <b>104</b> has one and preferably two longitudinal extents <b>151</b> a and <b>151</b><i>b</i>, which are each generally horizontally disposed on support <b>104</b> at the longitudinal ends thereof such that food tray <b>100</b> can be easily grasped by a crew person and maneuvered in and out of a compartment having substantially planar upper and bottom surfaces as will be discussed in further detail below. Additionally, support <b>104</b> typically includes a lip <b>152</b> which extends substantially around the entire periphery of support <b>104</b>, including longitudinal extents <b>151</b><i>a </i>and <b>151</b><i>b. </i>

In addition, support <b>104</b> preferably has handle portions <b>154</b><i>a </i>and <b>154</b><i>b </i>at opposing ends adjacent longitudinal extents <b>151</b><i>a </i>and <b>151</b><i>b</i>. Each handle <b>154</b> preferably has one or more depressed peripheral areas <b>156</b><i>a</i>, <b>156</b><i>b</i>, <b>156</b><i>c </i>and <b>156</b><i>d. </i>Support <b>104</b> includes at least one movable stop member, and preferably includes two movable stop members <b>158</b><i>a</i>, <b>158</b><i>b</i>. Movable stop member <b>158</b><i>a </i>is located on longitudinal extent <b>151</b><i>a </i>and movable stop member <b>158</b><i>b </i>is located on longitudinal extent <b>151</b><i>b. </i>

As illustrated in <figref idref="DRAWINGS">FIGS. 1-4</figref>, each movable stop member <b>158</b><i>a</i>, <b>158</b><i>b </i>preferably includes a tongue <b>160</b><i>a</i>, <b>160</b><i>b </i>and an upturned portion <b>162</b><i>a</i>, <b>162</b><i>b</i>. Preferably, each movable stop member <b>158</b><i>a</i>, <b>158</b><i>b </i>is defined by a U-shaped void <b>164</b><i>a</i>, <b>164</b><i>b</i>. Upturned portions <b>162</b><i>a</i>, <b>162</b><i>b </i>include inclined portions <b>166</b><i>a</i>, <b>166</b><i>b </i>which face disposable container <b>102</b>, radiused top edges <b>168</b><i>a</i>, <b>168</b><i>b</i>, and substantially vertical rear portions <b>170</b><i>a</i>, <b>170</b><i>b</i>. As such, movable stop members <b>158</b><i>a</i>, <b>158</b><i>b </i>can easily be depressed from an extended position to a retracted position and thereafter return to an extended position when abutted against a fixed surface. Preferably, movable stop members <b>158</b><i>a</i>, <b>158</b><i>b </i>are integrally formed with support <b>104</b> from plastic or any other suitable “food safe” material. As shown in <figref idref="DRAWINGS">FIGS. 1-4</figref>, upturned portions <b>162</b><i>a</i>, <b>162</b><i>b </i>of stop members <b>158</b><i>a</i>, <b>158</b><i>b </i>extend vertically above longitudinal extents <b>151</b><i>a </i>and <b>151</b><i>b </i>of support <b>104</b>. Alternatively, movable stop members <b>158</b><i>a</i>, <b>158</b><i>b </i>may include any other structure which enables movable stop members <b>158</b><i>a</i>, <b>158</b><i>b </i>to move from an extended position to a retracted position and return to the extended position. Reference is made to U.S. Pat. App. Pub. No. 2006/0045943, which is hereby incorporated by reference, for a more complete description of the general construction and operation of moveable stop members <b>158</b><i>a</i>, <b>158</b><i>b</i>. Additional desired features of tray <b>100</b> are discussed later especially as they relate to food staging device <b>500</b>.

In a second embodiment, food tray <b>200</b> is provided as illustrated in <figref idref="DRAWINGS">FIGS. 5-7</figref>. Food tray <b>200</b> may be identical to food tray <b>100</b> except that food tray <b>200</b> is vented. For convenience, the reference numerals for food tray <b>100</b> are the same as the item numbers for food tray <b>200</b> for similar items except that the item numbers for food tray <b>100</b> begin with <b>1</b> while item numbers for food tray <b>200</b> begin with <b>2</b>. Thus, food tray <b>200</b> has a container <b>202</b> with sidewall structure <b>210</b> and support <b>204</b> with support sidewall structure <b>238</b>. In addition, support <b>204</b> has moveable stop members <b>258</b><i>a, </i><b>258</b><i>b </i>with upturned portions <b>262</b><i>a</i>, <b>262</b><i>b </i>having a radiused top edge <b>268</b><i>a</i>, <b>268</b><i>b. </i>

Venting is provided by support openings <b>272</b><i>a</i>-<i>f </i>in support sidewall structure <b>238</b> and container openings <b>274</b><i>a</i>-<i>f </i>in container sidewall structure <b>210</b>. Openings <b>272</b><i>a</i>-<i>f </i>and <b>274</b><i>a</i>-<i>f </i>in combination provide venting passageways <b>276</b><i>a</i>-<i>f </i>between container interior volume <b>212</b> and the exterior atmosphere. Typically, one to ten openings are located in both sidewall structures <b>210</b> and <b>238</b>. As illustrated in <figref idref="DRAWINGS">FIGS. 5-7</figref>, three openings <b>272</b><i>a</i>-<i>f </i>and <b>274</b><i>a</i>-<i>f </i>are positioned in a spaced relationship along the length of each of sidewalls <b>224</b><i>a</i>, <b>224</b><i>b </i>and <b>246</b><i>a</i>, <b>246</b><i>b</i>. By spacing openings <b>272</b><i>a</i>-<i>f </i>and <b>274</b><i>a</i>-<i>f </i>along sidewalls <b>224</b><i>a</i>, <b>224</b><i>b </i>and <b>246</b><i>a</i>, <b>246</b><i>b</i>, various regions within interior volume <b>212</b> of container <b>202</b> are all relatively proximate to one of openings <b>272</b> and <b>274</b>.

Each of support openings <b>272</b> at least partially overlaps with at least one of container openings <b>274</b> to form a passageway <b>276</b>. Preferably, each of container openings <b>274</b> is substantially aligned with one of support openings <b>272</b>. Additionally, preferably each of openings <b>272</b> is of approximately the same size, and the same number of openings <b>272</b> appears on each of sidewalls <b>246</b><i>a</i>, <b>246</b><i>b</i>. Similarly, preferably each of openings <b>274</b> is of approximately the same size, and the same number of openings <b>274</b> appears on each of container sidewalls <b>224</b><i>a</i>, <b>224</b><i>b. </i>

In a typical quick-service restaurant, cooked food items, such as hamburger or chicken patties HP, are placed in a tray and then stored in a food holding heated storage device until used to make sandwiches. Typically, an open top tray is desired to allow convenient removal of a hamburger patty to meet the speed demands of a quick-service restaurant. During storage, the cooked food tends to progressively lose desired moisture and taste properties as the atmosphere of the interior is vented out the open top of a prior art container. Known approaches to reduce the rate of the loss of juice and taste properties of the food product have included limiting the amount of venting, particularly from the open top of the tray. It has been unexpectedly found that a limited amount of venting through a tray's sidewall does not increase the rate of loss of desired food quality, but instead acts to maintain superior taste quality for food held in the tray for extended periods of time, such as about 60 minutes or more for cooked hamburger patties HP, for example, stored at 160° F.

An additional advantage of tray <b>200</b> with replaceable container <b>202</b> is that different containers <b>202</b> can have openings <b>274</b> that are optimal for different specific foods while support <b>204</b> does not change. This advantage is particularly useful if new foods with different optimal openings <b>274</b> are introduced in a restaurant. Container <b>202</b> may be marked with an indicia (not shown) indicating the food that is optimally stored in container <b>202</b>.

Typically, openings <b>274</b> are circular in shape and have about the same diameter. Preferably, this diameter is in the range of about 5/16 inch to about 1¼ (5/4) inches, to provide a total cross-sectional opening area in the range of about 0.3 square inches to about 4.9 square inches for each opening <b>274</b>. As an alternative, openings <b>274</b> may be of a non-circular shape, preferably the cross-sectional area of each of such openings is also in about the same range of about 0.3 square inches to about 4.9 square inches. Openings <b>274</b> are preferably also spaced upwardly from container bottom <b>208</b> so that any juices that may escape from food contained within tray <b>200</b> do not leak out of an opening <b>274</b>. Openings <b>274</b> are also positioned downwardly from the top <b>206</b> to maintain structural integrity of container <b>202</b>.

Openings <b>272</b> can be in any desired configuration, including as a slit opening extending along the length or a portion of the length of the sidewalls. Openings <b>272</b> can also match openings <b>274</b> by location. However, support openings <b>272</b> may be larger than container openings <b>274</b> for flexibility purposes so that support <b>204</b> is suitable for use with different containers <b>202</b> having different openings <b>274</b> for different foods as discussed earlier. As shown in <figref idref="DRAWINGS">FIGS. 5-7</figref>, support openings <b>272</b> are of the same size and shape as container openings <b>274</b>.

More specifically, the desired food quality retention can be accomplished in accordance with the present invention by providing passageways <b>276</b> that have a total cross-sectional area (i.e. the sum of the total cross-sectional area of all passageways <b>276</b> at their narrowest point) that is selected in relationship to (i) the volume of interior space <b>212</b>, (ii) the inner surface area of sidewall structure <b>210</b> and/or (iii) the weight of the food that is maintained in tray <b>200</b>. Preferably, the ratio of the total cross-sectional area of passageways <b>276</b> in square inches to the size of interior volume <b>212</b> in cubic inches will be in the range of from about 1:2100 to about 1:13; more preferably the ratio is in the range of from about 1:140 to about 1:40; and most preferably the ratio is about 1:90. Preferably, the ratio of the total cross-sectional area of passageways <b>276</b> to the surface area of sidewall structure <b>210</b> is in the range of about 1:120 to 1:7, more preferably the ratio is in the range of about 1:80 to about 1:20; and most preferably the ratio is about 1:50. The surface area of sidewall structure <b>210</b> for the above ratio is the inner surface area of sidewall structure <b>210</b> rather than the outer surface. Preferably, the ratio of the total cross-sectional area of passageways <b>276</b> in square inches to the weight of the food held in tray <b>200</b> in pounds is in the range of about 1:30 to about 1:0.2, more preferably 1:1.85 to about 1:0.5, and most preferably about 1:1.35.

As illustrated in <figref idref="DRAWINGS">FIG. 6</figref>, the area of each container opening <b>274</b> is equal to the area of each support opening <b>272</b>. As illustrated in <figref idref="DRAWINGS">FIG. 6</figref>, the total cross-sectional area of passageways <b>276</b><i>a</i>-<i>f </i>is six times the cross-sectional area of a single container opening <b>274</b> or a single support opening <b>272</b> or <b>6</b> times Tr times the radius of opening <b>274</b> or opening <b>272</b> squared (6πr²). If container opening <b>274</b> is smaller than support opening <b>272</b> but everything else is the same as illustrated in <figref idref="DRAWINGS">FIG. 6</figref>, then the total cross-sectional area of passageways <b>276</b><i>a</i>-<i>f </i>is six times the cross-sectional area of a single container opening <b>274</b> or 6 times π times the radius of opening <b>274</b> squared. If container openings <b>274</b> and support openings <b>272</b> only partially overlap then only the overlapping areas count towards the total cross sectional area of passageways <b>276</b><i>a</i>-<i>f. </i>

In a third embodiment, tray <b>300</b> has a support <b>304</b> and container <b>202</b> as shown in <figref idref="DRAWINGS">FIGS. 10-11</figref>. Tray <b>300</b> has adjustable passageways <b>376</b><i>a</i>-<i>f </i>as illustrated in <figref idref="DRAWINGS">FIG. 11</figref>. For convenience, the item numbers for support <b>204</b> are the same as the item numbers for support <b>304</b> for similar items except that the item numbers for support <b>204</b> begin with <b>2</b> while item numbers for support <b>304</b> begin with <b>3</b>. Support <b>304</b> has a choke or slide member <b>380</b> mounted to support body <b>305</b> for reciprocal back-and-forth movement relative to support body <b>305</b>, to thereby allow adjustment of the size of passageways <b>376</b>. Slide member <b>380</b> may be formed of a unitary construction and may be molded of the same plastic or other food-safe material that is used to form tray <b>300</b>. Alternatively, slide member <b>380</b> may be formed in two or more parts that are securely joined together.

Slide member <b>380</b> has a first end <b>382</b>, a second end <b>384</b>, a first side <b>386</b> and a second side <b>388</b> that together provide an inner perimeter surface <b>390</b> which defines a mounting opening <b>392</b>. Mounting opening <b>392</b> is configured and sized to correspond to the upper portion of outer perimeter of sidewall structure <b>310</b> of support <b>304</b> along which slide member <b>380</b> is slideably mounted. Mounting opening <b>392</b> is made somewhat longer than the length of sidewall sides <b>346</b><i>a</i>, <b>346</b><i>b </i>to provide clearance space for longitudinal movement relative to support body <b>305</b>.

To mount slide member <b>380</b> to support body <b>305</b>, slide member sides <b>386</b>, <b>388</b> are manually spread apart to temporarily provide clearance over slide supports <b>394</b>. Slide supports <b>394</b> may be integrally formed with support sidewall sides <b>346</b><i>a</i>, <b>346</b><i>b </i>respectively, and outwardly protrude from sides <b>346</b><i>a</i>, <b>346</b><i>b</i>, respectively. Slide <b>380</b> is inserted over the sidewall structure <b>310</b>, until the top surface <b>396</b> of slide <b>380</b> abuts against the bottom surfaces of extents <b>351</b><i>a</i>, <b>351</b><i>b </i>and with slide sides <b>386</b>, <b>388</b> having cleared supports <b>394</b>. Slide member sides <b>386</b> and <b>388</b> are then released from their spread-apart position to slideably secure slide member <b>380</b> on support <b>304</b>. In addition to securing slide member <b>380</b>, supports <b>394</b> act as guides along which slide member <b>380</b> can slide. Tray lip <b>352</b> may also include a downwardly extending flange <b>397</b> to direct slide member <b>380</b> into proper alignment during mounting, and to additionally guide slide member <b>380</b> as it is longitudinally slid relative to support body <b>305</b>.

Slide member <b>380</b> has apertures <b>398</b><i>a</i>-<i>f </i>through slide member sides <b>386</b> and <b>388</b>. As slide member <b>380</b> is moved back and forth through its stroke, the position of apertures <b>398</b><i>a</i>-<i>f </i>relative to sidewall structure openings <b>372</b><i>a</i>-<i>f</i>, respectively, is changed to thereby adjust the amount of venting of container interior volume <b>212</b> through sidewall openings <b>274</b><i>a</i>-<i>f. </i>

Preferably, slide member <b>380</b> provides a simultaneous and equivalent size adjustment of all venting passageways <b>376</b><i>a</i>-<i>f</i>. This can be accomplished by locating openings <b>372</b> and apertures <b>398</b> in an arrangement such that when slide member <b>380</b> is mounted to support body <b>305</b>, openings <b>372</b> and apertures <b>398</b> are spaced a like distance apart. Stated another way, the locations for the center points of openings <b>372</b><i>a</i>-<i>f </i>and the center points of apertures <b>398</b><i>a</i>-<i>f </i>are chosen so as to provide for a substantially equal distance between the respective center points of openings <b>372</b><i>a</i>-<i>f </i>and apertures <b>398</b><i>a</i>-<i>f </i>when slide member <b>380</b> has been mounted to support body <b>305</b>. This arrangement allows all of passageways <b>376</b><i>a</i>-<i>f </i>to be simultaneously fully closed, fully opened, or variably opened the same percentage amount as slide member <b>380</b> is longitudinally slid relative to support body <b>305</b>.

Openings <b>372</b> and apertures <b>398</b> are preferably also arranged to provide convenient positioning of slide <b>380</b>. Passageways <b>376</b> are formed by support openings <b>372</b>, slide apertures <b>398</b>, and container openings <b>274</b>. Generally, support openings <b>372</b> and container openings <b>274</b> are of the same size and coincide. Preferably, passageways <b>376</b> are caused to be in the fully opened position when the stroke of slide member <b>380</b> is terminated in a first direction, and providing for a fully closed position for passageways <b>376</b> when the stroke of slide member <b>380</b> is terminated during movement in the opposite direction. Stated another way, when slide member <b>380</b> is moved to a position where slide member first end <b>382</b> abuts sidewall structure first end <b>348</b><i>a </i>to terminate further movement in that direction, openings <b>372</b><i>a</i>-<i>f </i>and apertures <b>398</b><i>a</i>-<i>f </i>are fully aligned and passageways <b>376</b><i>a</i>-<i>f </i>are fully opened. When slide member <b>380</b> is moved the full extent in the opposite direction to a point where second slide end <b>384</b> abuts tray sidewall structure second end <b>348</b><i>b</i>, openings <b>372</b><i>a</i>-<i>f </i>and apertures <b>398</b><i>a</i>-<i>f </i>are fully unaligned, i.e., slide member <b>380</b> is at the fully choked position, substantially closing off passageways <b>376</b><i>a</i>-<i>f</i>. Such arrangement allows a user to reliably and quickly move slide member <b>380</b> to fully opened or fully closed positions without closely inspecting the alignment of slide member apertures <b>398</b> relative to openings <b>372</b>. Alternatively, the movement of the stroke of slide member <b>380</b> may be terminated by having slide member <b>380</b> contact other points on support <b>304</b>.

Sidewall structure <b>310</b> has an upper portion <b>404</b> that has an outwardly projecting rim <b>406</b> having an outer surface <b>408</b> with a radiused bottom edge <b>410</b>. Slide member <b>380</b> has an inwardly depending radiused flange <b>412</b> having an inner surface that slideably mates with radiused bottom edge <b>410</b> of rim <b>406</b>. The mating of rim bottom edge <b>410</b> and flange <b>412</b> helps prevent foreign particles from entering between slide member <b>380</b> and rim <b>406</b>. Such entrance of foreign particles is undesirable because it could interfere with the sliding motion of slide member <b>380</b>, or allow foreign particles to find their way into interior volume <b>212</b> of container <b>202</b> via openings <b>274</b>.

Support body <b>305</b> includes a passageway opening gauge <b>418</b> for use in setting the size of passageway openings <b>376</b> and to indicate the position of slide member <b>380</b> relative to openings <b>372</b>. Gauge <b>418</b> includes a mark or line <b>420</b> on slide member <b>380</b>, and a plurality of spaced apart calibrated marks or lines <b>422</b><i>a</i>-<i>c </i>on support body <b>305</b>. When line <b>420</b> is vertically aligned with line <b>422</b><i>b</i>, slide member <b>380</b> has been moved to a predetermined partially opened condition for passageways <b>376</b>, for example ½ open. When line <b>420</b> is vertically aligned with line <b>422</b><i>a</i>, slide member <b>380</b> has been positioned so that passageways <b>376</b> are fully closed. Vertical alignment of line <b>420</b> and line <b>422</b><i>c </i>indicates that slide member <b>380</b> has been positioned to the fully opened position for passageways <b>376</b>.

Lines <b>420</b> and <b>422</b><i>a</i>-<i>c </i>may be integrally formed in slide member <b>380</b> and support body <b>305</b>, respectively, such as in the form of a ridge or groove, or may be provided in other manners, such as lines printed onto the surfaces of support body <b>305</b> and slide member <b>380</b>. Indicia may also be provided to indicate the extent passageways <b>376</b> are open or closed, such as indicia adjacent lines <b>422</b><i>a</i>-<i>c </i>with a notation of “closed,” “½,” and “opened,” respectively. Additional calibrated lines <b>422</b> may also be provided, if desired, to indicate additional settings for passageways <b>376</b>, i.e., ¼ opened, ¾ opened, etc.

In a further aspect of the invention, support <b>305</b> is provided with a mechanism <b>426</b> to secure slide member <b>380</b> at a selected position. Support body <b>305</b> is provided with an outwardly projecting detent or lug <b>430</b>, while inner surface <b>390</b> of first side <b>386</b> of slide member <b>380</b> has three spaced apart indentations or recesses <b>432</b><i>a</i>-<i>c</i>. As slide member <b>380</b> is moved to a fully opened position for passageways <b>376</b>, lug <b>430</b> moves into recess <b>432</b><i>c</i>. In this position, lug <b>430</b> cooperates with recess <b>432</b><i>c </i>to secure slide member <b>380</b> at the fully opened position. This engagement prevents slide member <b>380</b> from inadvertently being moved away from the selected fully opened position during the handling of tray <b>300</b>. Pushing or pulling on handles <b>433</b><i>a </i>or <b>433</b><i>b </i>with a moderate force, however, causes lug <b>430</b> to disengage from recess <b>432</b><i>c </i>to allow slide member <b>380</b> to be selectively moved to the partially opened position, or to the fully closed position, as desired. In the partially opened position, slide member <b>380</b> is secured in position by cooperation of lug <b>430</b> engaging recess <b>432</b><i>b</i>. When slide member <b>380</b> has been moved to the fully closed position, slide member <b>380</b> is maintained in position by lug <b>430</b> engaging recess <b>432</b><i>a</i>. Support <b>304</b> may be provided with additional intermediate locking settings (not shown) for passageways <b>376</b> by providing additional recesses <b>432</b> positioned between recesses <b>432</b><i>a </i>and <b>432</b><i>c. </i>

A recommended setting guide <b>436</b> may also be provided to indicate recommended slide member positions based on the food type to be held in tray <b>300</b>. Recommended setting guide <b>436</b> may be in the form of a sticker adhered to support body <b>305</b> or to slide member <b>380</b>. Alternatively, recommended setting guide <b>436</b> may be molded integrally with support body <b>305</b> and/or slide member <b>380</b>. Recommended setting guide <b>436</b> includes indicia indicating one or more food types, for example “HP” <b>438</b> for hamburger patty and “CHK” <b>439</b> for chicken breasts. Also included are visually readable graphical depictions <b>440</b> and <b>442</b> showing the recommended spacing of openings <b>372</b> relative to apertures <b>398</b> for a selected food type.

In an alternative embodiment not shown, rather than having a single slide member <b>380</b>, support <b>304</b> has mounted thereto two separate slide members, one for sidewall <b>346</b><i>a </i>and one for sidewall <b>346</b><i>b. </i>

Food Staging Device

In another aspect of the invention, a food staging device <b>500</b> is provided. As shown in <figref idref="DRAWINGS">FIGS. 8-9</figref>, food staging device <b>500</b> has a plurality of heated compartments <b>502</b><i>a</i>-<i>d </i>for storing at least one, and preferably a plurality of food trays in accordance with the present invention. <figref idref="DRAWINGS">FIGS. 8 and 9</figref> show food staging device <b>500</b> with food trays <b>100</b>.

Each of compartments <b>502</b><i>a</i>-<i>d </i>is bounded by an upper compartment surface <b>518</b><i>a</i>-<i>d </i>and a lower compartment surface <b>520</b><i>a</i>-<i>d</i>. Preferably, upper surfaces <b>518</b><i>a</i>-<i>d </i>are heated. Preferably, lower surfaces <b>520</b><i>a</i>-<i>d </i>are heated. Upper heated compartment surfaces <b>518</b><i>a</i>-<i>d </i>and lower compartment surfaces <b>520</b><i>a</i>-<i>d </i>are preferably constructed from a material having a high thermal conductivity and preferably are constructed from anodized aluminum. Moreover, each of upper heated compartment surfaces <b>518</b><i>a</i>-<i>d </i>and lower heated compartment surfaces <b>520</b><i>a</i>-<i>d </i>are substantially flat and substantially horizontal to provide uniform heat transfer to any one of food trays <b>100</b><i>a</i>-<i>d </i>stored therein and to enable easy sliding of any one of trays <b>100</b><i>a</i>-<i>d </i>along the surface of lower heated compartment surfaces <b>520</b><i>a</i>-<i>d</i>. Steam is not used to directly heat food, such as hamburger patties HP, in trays <b>100</b>.

Upper angled portions <b>514</b> and <b>515</b> in conjunction with stop members <b>158</b><i>a</i>, <b>158</b><i>b </i>cooperate to keep tray <b>100</b> within compartment <b>502</b>. Unless the user applies a force on tray <b>100</b> in excess of a threshold force which would move one of stop members <b>158</b><i>a</i>, <b>158</b><i>b </i>downwards can tray <b>100</b> be removed from compartment <b>502</b>.

As can best be seen in <figref idref="DRAWINGS">FIG. 4</figref><i>a</i>, support <b>104</b> has a height <b>172</b> defined by the distance between top surface <b>174</b> of longitudinal extent <b>151</b><i>a </i>and a lower edge <b>176</b> of sidewall structure <b>138</b>. Height <b>172</b> does not take into account the height of movable stop members <b>158</b><i>a</i>, <b>158</b><i>b</i>. Disposable container <b>102</b> has a height <b>178</b> defined by the distance between top surface <b>180</b> of lip <b>130</b> and a bottom surface <b>181</b> of bottom <b>108</b>. For each food tray <b>100</b><i>a</i>-<i>d</i>, heights <b>172</b> and <b>178</b> are less than a height <b>522</b> of compartments <b>502</b><i>a</i>-<i>d </i>into which trays <b>100</b><i>a</i>-<i>d </i>are to be inserted. In other words, height <b>172</b> of support <b>104</b> and height <b>178</b> of container <b>102</b> are chosen so that there are predetermined distances <b>182</b> and <b>184</b>, respectively, from upper compartment surfaces <b>518</b><i>a</i>-<i>d </i>when trays <b>100</b><i>a</i>-<i>d </i>are placed within any one of compartments <b>502</b><i>a</i>-<i>d</i>. One or both of predetermined distances <b>182</b> and <b>184</b> are preferably between about 0.00″ and 0.09″, more preferably between about 0.04″ and 0.08″, and most preferably about 0.06″. Controlling one or both of predetermined distances <b>182</b> and <b>184</b> controls vapor transfer out of the volume <b>112</b> of trays <b>100</b><i>a</i>-<i>d</i>, thereby also controlling the fluid loss of the cooked food portions in trays <b>100</b><i>a</i>-<i>d</i>. Such control of fluid loss is critical for cooked food stored in trays <b>100</b><i>a</i>-<i>d</i>, such as egg products, hamburger patties, grilled chicken, pork sausage and Canadian bacon to maintain the appearance, texture, temperature, and taste thereof.

Generally, the height of disposable containers <b>102</b> is slightly higher than the working height of support <b>104</b>, such as at recessed portion <b>142</b> and thus there is a typically relatively small gap distance <b>186</b>. Gap <b>186</b> is the vertical distance that bottom of lip <b>130</b> is above recessed portion <b>142</b> immediately below lip <b>130</b> when tray <b>100</b> is supported by a level surface. Preferably, recessed surface <b>142</b> is the portion of longitudinal extent <b>151</b> immediately below lip <b>130</b>. Gap distance <b>186</b> is typically greater than about 0 inches to about 0.2 inches, or more, if desired. This arrangement ensures that bottom <b>108</b> of disposable container <b>102</b> will be in contact with the surface on which tray <b>100</b> is placed, such as one of lower compartment surfaces <b>520</b><i>a</i>-<i>d </i>of food staging device <b>500</b>. This helps to ensure good heat transfer through bottom <b>108</b> of disposable container <b>102</b>.

Methods

The invention includes methods of storing cooked food items and methods of handling cooked food portions, such as to be incorporated in a sandwich in a restaurant. The methods include providing a container having an open top, a bottom and a sidewall structure, the bottom and the sidewall structure defining an interior volume and providing a support having a support opening. Next, the container is placed into the support opening thereby forming a tray and the cooked food items or portions are placed in the tray to at least partially fill the interior volume. Preferably, the interior volume is filled to at least half full. Next, the tray having the cooked food therein is placed into a compartment having a heated surface so that the bottom of the container contacts the heated surface to maintain the temperature of the food in a desired elevated temperature range. Generally, the compartment may be one of many compartments of a food holding device, such as food staging device <b>500</b>.

Immediately before or after placing the tray in the compartment, a timer can be set for a predetermined time period as desired, which can be for more than 15 minutes, depending on the food. The predetermined time period can correspond to a length of time after which the food portions are not considered to have a high enough quality to serve.

After storage for a period of time, the cooked food item or portion is removed from the compartment. Generally, the cooked food item or portion is removed only after an order has been placed by a customer for a sandwich or meal incorporating the cooked food item. To remove the food item from the compartment, the tray is partially or completely removed from the compartment and the food item is removed from the tray. The period of time can be more than about 15, 30 or 45 minutes, for example. The period of time can be less than 4, 3, 2 or 1 hours, for example. A sandwich is assembled using the cooked food portion from the tray.

Once the tray has been emptied, the container may be reused if the container has been used for only a short period of time. Generally, the container will be removed from the support and a second, unused container will be placed into the support to form a new tray. The newly assembled tray can then be used for storing a cooked food item or handling cooked food portions to be incorporated in a sandwich as described above.

While the invention has been described with respect to certain preferred embodiments, as will be appreciated by those skilled in the art, it is to be understood that the invention is capable of numerous changes, modifications and rearrangements and such changes, modifications and rearrangements are intended to be covered by the following claims.